Metal stud and track former

ABSTRACT

A portable roll forming machine for the job site fabrication of metal studs and track members for use therewith. One roll pass combination alternately provides these channel sections of different width. Power actuated flying punch and cut-off components provide openings for the through passage of utilities and cut lengths of studs and track that are regulable to correspond to job site requirements.

United States Patent Allen 1 June 10, 1975 [54] METAL STUD AND TRACK FORMER 2,708,958 5/1955 Crafton 1. 72/181 3,051,214 8/1962 Rutten 72/129 1751 memo" Denver, Colo 3,720,995 3/1973 Brown 29/155 R [73] Assignee: Watertite Industries, Inc., Denver,

Colo. Primary Examiner-C. W. Lanham 1 Assistant Examiner-Robert M. Rogers [22] Flled 1973 Attorney, Agent, or Firm-C B. Messenger [21] Applt No.: 419,308

[57] ABSTRACT 2% i 72/129; gz lf i l g A portable roll forming machine for the job site fabri- 'f 9 5 g cation of metal studs and track members for use therel o earc 230; {52% with. One roll pass combination alternately provides 9/ these channel sections of different width. Power actuated flying punch and cut-off components provide [56] References cued openings for the through passage of utilities and cut UNITED STATES PATENTS lengths of studs and track that are regulable to corre- 491860 3/1893 Fay 72/185 spond to job site requirements. 1,673,787 6/1928 Frahm 72/181 2,251,967 8/1941 Yoder 1. 72/181 9 Clam, 7 Drawmg Flgures METAL STUD AND TRACK FORMER BACKGROUND OF THE INVENTION Many present building construction projects use metal studs when wall partitions or even exterior panels are being fabricated. The studs which are used to support wall panels are of a regulated cross-sectional size and configuration and usually the stud elements are disposed to extend between track elements that are themselves of channel cross-section. The track is fixed by fasteners to the floor and ceiling of a building, and the studs are then extended between the floor and ceiling tracks and joined to the track. The interior flange to flange width of the track usually corresponds to the exterior width of the studs so that the studs are closely received within the track. The track and studs are joined together by welding or by power driven self-drilling and tapping screws. In present practice studs of the desired material and shape are rolled by forming machines at a manufacturing site and are thereafter bundled for delivery to the separate job sites. Since the floor to ceiling heights of buildings where the studs are used are varied, studs of conventional length are usually provided and often must be cut before installation to accommodate non-standard installations or to compensate for job site irregularities. Necessarily, a lot of expensive journeyman labor is expended at the work site to fit the studs to the particular installation conditions and/or the studs do not extend the full distance between the webs of the spaced apart tracks. Wall loadings are, accordingly, transmitted only by the particular fasteners used. The track itself is also provided in standard lengths, and extensive cut and fit operations are involved so that the track will extend the required distance between doorways or terminal walls.

Since sturdy and economical wall systems may be fabricated through use of metal studs and track, it seems desirable to improve the material handling and job site fabrication characteristics for such construction elements.

SUMMARY OF THE INVENTION The present invention provides a roll pass machine that is of minimum size and weight and that can, accordingly, be moved to job sites or from floor to floor at such job sites. The machine has an integral powered drive system and a power actuator system that is directly connectable to a facilities power source or to a provided power generator. A rotary cradle is provided on the machine for the reception of a coil of flat strip material. The material is continuously fed through a plurality of roll pass combinations to form metal studs of an overall channel shape having reinforced return lips providing a *C section. The same machine and most of the same roll stands are also used to form track members that are of channel section but of greater width than said stud sections. The greater width for the track members is derived through use of a single roll that is alternately positionable with respect to a finishing stand in the mill for cooperative action with the bottom roll forming member at said stand or out ofcontact therefrom. When this track finishing roll is in position of engagement, a radius previously provided in the stud forming operations is flattened. As the bend radius is decreased. an increased width is provided between the webs of the track channel whereby the stud members may be received within the track channel. Power actuated flying punch and cut-off members are supported on slide elements of the roll mill structure. A source of fluid power is interconnected to said cut-offs and punches for the actuation thereof. The flying cut-off is a sheer device which engages the studs or track to cut a narrow section therefrom thereby severing the section being rolled. Other fluid powered elements actuate punches to provide holes through the webs of the section being rolled at regulated spaced positions. As the punches or cut-off engage the rolled section, such members are themselves moved along their support rails together with the rolled section so that the roll forming operations are not interrupted. Automatic gauge and actuation equipment is provided so that studs or track members of the desired and regulable length are provided. Accordingly, the track and studs can all be cut to a specific length so that such members can be closely fitted to the building construction operation then being carried on.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a perspective view of the roll forming machine,

FIG. 2 is a perspective view of a partial wall assemy.

FIG. 3 is an end perspective view showing the stud cross-section,

FIG. 4 is an end perspective view showing the track cross-section,

FIG. 5 is a front elevation of a ninth roll stand used in the forming of the stud section,

FIG. 6 is a front elevation ofa tenth or finishing roll stand with the alternately used forming roll in position to complete the track cross-section, and

FIG. 7 is a front elevation ofa first roll stand illustrating the different widths for the stud section material and the narrower track section material.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The roll forming machine of the present invention is shown in FIG. 1. In this FIG. the forming machine 11 has side frame walls 12 extending longitudinally and providing support for a plurality of roll stands disposed within such machine. A roller cradle 13 is adapted to receive and hold a coil of metal strip which preferably should be galvanized or other finished material. The roll stands disposed within the forming machine 11 may be adjusted so that material from 20 to 30 gauge can be handled. A single thickness or take-off end I4 is uncoiled from the coil I5 of strip material and fed into the first roll stand of the machine. Such first stand of rolls is shown in FIG. 7. If studs are to be formed, the strip material will be offull width as illustrated. Accordingly, the top roll 16 will depress the outer edges 17 and 18 of the strip material 14 into the forming roll 19. This initial bend provides a reinforced roll edge for the return segments 21 and 22 of the C" section stud 30. In subsequent roll stands these edges 17 and 18 are bent backwardly into tight contact with the material of the return sections 21 and 22 for the stud. If track sections are to be formed, the coil of material 15 will be of narrower width, since the return sections and rolled edges l7, 18, 21, 22 are not provided. The width of material used for the track sections is indicated by the dimension B in FIG. 7.

As the strip material courses through successive roll stands within the machine, the flanges of either the track or the studs will be raised to a 90 position with respect to the webs, and where the wider material is used the return segments 21 and 22 having the rolled edges 17 and 18 will be formed and moved to the posi' tion shown in FIG. 3. For the track sections, the web is numbered 23 and the flanges are 25 and 26. The stud section web is number 24 and the flanges are 27 and 28.

The ninth stand of rolls, as shown in FIG. 5, forms section strengthening corrugations 29 disposed longitudinally along the lengths of the stud or track webs. The vertically disposed rolls 32 shown in FIG. 3 mark and score the outer surfaces of the flanges providing the multiple indentations 31 illustrated in FIGS. 3 and 4. These vertical rolls 32 may be disposed between the roll stands 9 and or just ahead of the ninth roll stand. Roll stand 8 just preceding the roll shown in FIG. 5

forms edge stiffening sections 33 and 34 and starts formation of radius bends 35 and 36 which interconnect the webs and flanges of either the studs 30 or tracks 20.

The radius bends 35 and 36 are completed in the forming rolls shown in FIG. 5. These bends are of relatively large radius but still provide a strong structure for the studs 30. Whether track or studs are being formed, the sections will move past the forming roller 37 of the tenth roll stand. as shown in FIG. 6. If studs are being formed, the finishing roll 38, its supporting shaft 39 and bearing supports 4] will be moved upwardly to an alternate out-of-way position away from contact with the formed studs. Pivotally movable support arms 42 for the roll 38 are provided within the frame 12 of the roll machine II for movement about pivot supports 43, as shown in FIG. 1. As studs are being formed, the side flanges 44 of the forming rolls 37 still engage the flanges 27 and 28 of the stud section to further establish the right angular position for these flanges and to straighten the stud sections.

If track is being formed, the pivot arms 42 will be moved to a lowered position bringing the roll 38 into the position illustrated in FIG. 6. Mating rolls 37 and 38 of this tenth pass or finishing stand then operate to reduce the radius of curvature of the previously formed bends 35 and 36 thereby providing bends 45 and 46 of lesser radius. This reduction of bend radius is used to move the side flanges and 26 outwardly to more widely spaced positions so that the inner dimension between the flanges 25 and 26 then corresponds to the outer dimension of the stud flanges 27 and 28. Due to this wider section, the tracks 20 which are positioned along the floors and ceiling of building structures can receive the studs which are extended therebetween. If the studs are of proper length, the webs 24 of the studs 30 will extend the full distance between the webs 23 for the floor and ceiling track members 20. If the studs are of proper length to extend such full distance, loads will be transmitted by the studs themselves rather than by the fasteners that may be used.

In FIG. 2 self-drilling and tapping screws 47 have been used that extend through the flange 26 ofthe floor track 20 and through the flange 27 of the studs 30. The score markings 31 provided on the exterior surfaces of such flanges provide a center that will tend to prevent wobbling of self-drilling and tapping screws as they are forced into contact with the flanges by power driving apparatus. Since these score markings extend the full length of both the studs and tracks, wallboard screws used to hold wallboard or other paneling completing the wall will likewise be self-centered as they are applied.

Further features of the present invention are shown in FIG. 1, where it will be seen that the portable roll forming machine 11 provides support for flying cut-off and punch mechanisms. Power cyclinders 51, 52 and 53 that are actuated by hydraulic fluids, compressed air or other means are used to power a flying cut-off mech anism 60 or the hole punches 62 and 63. The flying cutoff mechanism 60 has side plates 54 and 55 with a cutting blade of relatively thin section disposed therebetween. The blade (not shown) and the side plates 54 and 55 all provide a shaped opening 56 through which the stud or track sections will extend. If the cyclinder 51 is actuated, the piston thereof will move the blade thereby severing a small segment from the roll section being formed. The severed segment is itself expelled out the bottom of the flying cut-off mechanism 60. Actuation of the cylinders 52 and 53 will cause movement of pistons therein to drive the punches 62 and 63 downwardly through the section being formed and through a die element below the formed section (not shown). The punches 62 and 63 are used to provide the holes 72 and 73 shown in the studs of FIG. 2. The cylinder 52 is disposed a regulated distance away from the cutoff cylinder 51, and, accordingly, all of the holes 72 will be in regulated aligned positions adapted to receive electrical or other utilities 74 that may be threaded therethrough when the wall is erected. The holes 73 are provided for similar purposes, and they too are disposed a regulated distance away from the cut ends of the studs 30. A threaded adjusting rod 75 interconnects the power actuated assemblies 51 S2 and 53 so that the hole separation distances can be closely set, as required.

All of the power actuator mechanisms 51, 52, 53 and the flying cut-off mechanism 60 and punches 62 and 63 are supported on the cold roll mill 11 by the top mounted guide rods 76 and a lower slide 77. Accordingly, this total cut-off assembly can move longitudinally with respect to the machine structure. Desirably, all of these components making up a cut-off assembly should move with the section being formed, so the cutoff and punch operations can be accomplished without interruption of the roll forming procedures. As soon as the cutting blade of the cut-off 60 or the punches 62 or 63 come into contact with the material being formed, the entire cut-off assembly inclusive of the power cylinders SI, 52, 53 will be moved reciprocally along rods 76 and slide 77 at a rate corresponding to the speed of the section being formed. When the cut-off and punch operations are completed, the blades and punches will be retracted, and the total cut-off assembly can be returned by spring or other power means to an at-rest position.

Actuation of all or any of the powered actuators of the cut-off assembly can be controlled by an operator control button 80 that is hand-held or that can be mounted on the machine. Automatic control is also provided by a line 81 that extends downstream away from the machine 11 to an adjustably positionable automatic switch 82 disposed on a rollout table or similar support for the material being extruded. When the extruded section touches the contact 83 of switch 82, the cylinders 51, 52 and 53, or selected ones thereof, will be actuated to cut off a desired length of material and- /or to punch holes 72 and 73, etc. a fixed distance away from the end of the next piece to be formed. The position of the switch 82 can be closely adjusted, and, accordingly, the length of the studs or track being out can be regulated on a per piece basis so that each stud or track piece could be of a different length as necessary to assure correct interfitting of the studs and track with each stud extending a full distance from the floor and ceiling track webs and with the track being of proper and uninterrupted length for a full wall section. Since the track has bends 45 and 46 of lesser radius, the studs can be closely interfitted in the track, and an efficient load transmission is accomplished that is not dependent on the strength of welds or fasteners used.

The described bends of lesser radius for the track section actually make it possible to provide the two mating channel sections, one of which can be received within the other. An intermediate stand of rolls initially locate and/or provide the radius bends 35 and 36. These bends are of essentially regular curvature, and the bend lines therefor are disposed in equidistant positions with respect to the adjacent webs and flanges. Both the stud and track sections initially pass such intermediate roll stand, and the bends for each are initially of the same configuration. When track sections are being formed, however, the top roll 38 of the tenth pass stand is moved into position as shown in FIG. 6. The mating rolls 37 and 38 of this tenth pass or finishing stand operate to flatten a web related portion of the radius bends initially provided at the same time that new bends 45 and 46 of lesser curvature are formed at wider spaced positions so that the bend lines for the new bends 45 and 46 are actually disposed at laterally spaced positions a greater distance apart than the initial bend lines for the radius bends 35 and 36. The rolls of such finishing stand have a dual operation in flattening a portion of the previous radius bend and in providing new radius bends having bend lines at a greater distance apart. In connection with such operation, it should be noted that an opposite result is obtained if the radius of bend is decreased in a subsequent roll pass and the bend line is not moved. With this alternate operation the channel section passing the finishing stand might be nestable within the channel section having the larger bend radius. This described alternate technique would not be as satisfactory in connection with fabrication of stud and track elements. since the bends of larger radius would then be in the track section where the bends themselves might interfere with close interfitting of the studs.

1 claim:

1. A portable roll forming machine for the fabrication of structural channel sections from coil strip materials wherein at least two of the channel sections formed by said machine are to be of different width comprising a plurality of pass roll stands in circuit arrangement one after another, an intermediate roll stand having mating top and bottom rolls adapted to provide flange related initial radius bends at laterally spaced bend lines whereby the flanges of either channel section are moved to a position that is normal with respect to the web of such section with the flanges of each section being disposed apart the same distance, and a following roll stand disposed in operative position after said intermediate stand having mating top and bottom rolls adapted to selectively reduce the radius of said initial flange related bends and to laterally move the flanges for channel sections worked by said following roll stand whereby the flanges of such worked channel sections are adapted for close interfitting engagement with the flanges of channel sections passing only through said intermediate roll stand.

2. The forming machine as set forth in claim 1 wherein the bends of lesser radius have bend lines at an increased laterally spaced position apart.

3. The forming machine as set forth in claim 2 wherein the mating rolls of said following roll stand flatten a web related portion of the initially derived radius bends.

4. The forming machine as set forth in claim 1 wherein one roll of the following roll stand is positioned for engagement with said flange to further move the flanges of either channel section to normal position and for the straightening of such channel sections.

5. The forming machine as set forth in claim 4 wherein the other roll of said following roll stand is used only in connection with the formation of channel sections having laterally moved flanges.

6. The forming machine as set forth in claim 3 wherein said machine is used to selectively form metal track and stud channel components for nested interengagement one with another for use in the fabrication of wall panels with said intermediate roll stand providing the stud channels.

7. The forming machine as set forth in claim 6 wherein the combined use of said intermediate and following roll stands provides track channel sections for said wall panels that are of greater width than said studs.

8. The forming machine as set forth in claim 6 and further comprising coils of strip materials of alternate widths for use in the fabrication of said stud and track components wherein coil strip material of lesser width is used to form the track channel sections that are of the greater width.

9. The forming machine as set forth in claim 6 and further comprising a flying cut-off mechanism supported on said forming machine and adapted for reciprocal movement with respect thereto in a direction aligned with the movement pattern for said strip materials whereby the channel sections formed by said machine may be cut off without interruption of the roll forming operations, and punch elements adapted to provide utility openings through said channel sections mounted on said machine for conjoint movement with said flying cut-off. 

1. A portable roll forming machine for the fabrication of structural channel sections from coil strip materials wherein at least two of the channel sections formed by said machine are to be of different width comprising a plurality of pass roll stands in circuit arrangement one after another, an intermediate roll stand having mating top and bottom rolls adapted to provide flange related initial radius bends at laterally spaced bend lines whereby the flanges of either channel section are moved to a position that is normal with respect to the web of such section with the flanges of each section being disposed apart the same distance, and a following roll stand disposed in operative position after said intermediate stand having mating top and bottom rolls adapted to selectively reduce the radius of said initial flange related bends and to laterally move the flanges for channel sections worked by said following roll stand whereby the flanges of such worked channel sections are adapted for close interfitting engagement with the flanges of channel sections passing only through said intermediate roll stand.
 2. The forming machine as set forth in claim 1 wherein the bends of lesser radius have bend lines at an increased laterally spaced position apart.
 3. The forming machine as set forth in claim 2 wherein the mating rolls of said following roll stand flatten a web related portion of the initially derived radius bends.
 4. The forming machine as set forth in claim 1 wherein one roll of the following roll stand is positioned for engagement with said flange to further move the flanges of either channel section to normal position and for the straightening of such channel sections.
 5. The forming machine as set forth in claim 4 wherein the other roll of said following roll stand is used only in connection with the formation of channel sections having laterally moved flanges.
 6. The forming machine as set forth in claim 3 wherein said machine is used to selectively form metal track and stud channel components for nested interengagement one with another for use in the fabrication of wall panels with said intermediate roll stand providing the stud channels.
 7. The forming machine as set forth in claim 6 wherein the combined use of said intermediate and following roll stands provides track channel sections for said wall panels that are of greater width than said studs.
 8. The forming machine as set forth in claim 6 and further comprising coils of strip materials of alternate widths for use in the fabrication of said stud and track components wherein coil strIp material of lesser width is used to form the track channel sections that are of the greater width.
 9. The forming machine as set forth in claim 6 and further comprising a flying cut-off mechanism supported on said forming machine and adapted for reciprocal movement with respect thereto in a direction aligned with the movement pattern for said strip materials whereby the channel sections formed by said machine may be cut off without interruption of the roll forming operations, and punch elements adapted to provide utility openings through said channel sections mounted on said machine for conjoint movement with said flying cut-off. 